Installation and maintenance guide

Digital grease flow detector

Model 800030

Date of issue July 2016

Form number 400101B

Read manual prior to installation or use of

this product. Keep manual nearby for
future reference.
Table of contents
DANGER

Explanation of safety signals. . . . . . . . 2 Indicates hazardous situation which, if not

avoided, will result in death or serious
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 injury.
Introduction . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . 4

Detector disassembly. . . . . . . . . . . . . . . 5

Detector re-assembly . . . . . . . . . . . . . . 6 WARNING

Service parts/kits. . . . . . . . . . . . . . . . . . 7 Indicates hazardous situation which, if not

avoided, may result in death or serious
Troubleshooting. . . . . . . . . . . . . . . . . . . 8 injury.
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . 10

Explanation of safety signals

CAUTION

Indicates hazardous situation which, if not

avoided, could result in minor or moder-
ate injury.

Safety alert symbols identify potential

physical injury hazards. Obey all safety
messages below this symbol to avoid pos-
sible injury or death.
SAFET Y INSTRUCTION

Protection of device may be impaired if

used in a manner not specified by
manufacturer.
SAFET Y INSTRUCTION

Safety instruction sign indicates specific

safety-related instructions or procedures.

2
Safety Introduction
Read and observe operating instructions Model 800030 a positive displacement flow
before installing and operating the flow detector consisting of oval gears. One gear has
detector. a built-in diametric magnet. As the magnet
Do not attempt to install, use, or trouble- turns with the gear, a rotating motion of
shoot prior to fully understanding all safety magnetic flux results.
and operational instructions. As the magnet rotates, a hall sensor detects
the magnet flux motion. This motion is
processed by an encoder creating and sending
Application a digital signal to an outside controller.
A blinking LED indicates processed signals.
Model 800030 was designed to generate a
confirmation signal to verify lubrications
events of a critical lubrication point. The unit
would be installed between the lubrication
! Notice
Follow all local safety regulations
regarding installation, use and
point of the bearing and the lubricating device
maintenance.
like the injector. Signals are communicated to
SKF LMC 301 or PLC. Detecting both small
0.002 in. 3 (32 mm3) and large
0.5 in. 3 (8 195 mm3) flow of grease.

Specifications

Media Grease grade 0 to 2

Grease ports 1 / 8 in. NPTF
Wetted parts Aluminum, steel, nitrile, rubber and nylon

Maximum pressure 3,000 psi (206 bar)

Maximum operation temperature 140 °F (60 °C)
Minimum operation temperature –30 °F (–34 °C)

Sensitivity 1) 0 – 140 °F –17 – 60 °C) 0.002 – 0.5 in 3 (32 – 8 195 mm3) per signal generated
–30 – 0 °F (–34 – 17 °C) 0.005 – 0.5 in 3 (81,9 – 8 193 mm3) per signal
Maximum altitude 10,000 ft. *3 048 m)
Maxiumum humidity 100%

Dimensions 2 x 1.6 x 1.9 in. (51 x 42 x 48 mm)

Protection IP67
Weight 0.35 lbs. (0.159 kg)

Supply voltage 12 to 30 V DC
Polarity protection 12 to 30 V DC
Nominal supply current 5 mA

Maximum supply current 35 mA

Output signal 12 to 30 V DC
Maximum output signal 30 mA

1) Entrapped air may compromise minimum sensitivity level.

3
Installation Installation procedure
1 Shut off all grease flow through grease
Installation guidelines line.
• Units are non-directional. 2 Attach inlet and outlet connections to flow
• Use thread sealant on all pipe threads. detector.
• Do not overtighten line connections. 3 Attach one end of connector cable to flow
• Perform system tests, checking for proper detector.
functioning and connection sealing. 4 Attach remaining end of connector cable
to controller.
5 Test detector by opening grease line to
supply grease flow to detector.
6 Verify LED is blinking, indicating that the
flow detector is working properly.
Notice
! Grease flow detector is to be in-
stalled in-line with grease line so that
flow of lubricant is directed through
sensor.
Assembly has an IP67 environmental
rating and does not require additional Notice
enclosures.
! Detector requires a controller that
Sensor is approved for indoor/outdoor accepts digital signal via a connector
use. assembly part no. 280137.

Notice
! Connector cable must be ordered
WARNING
separately.
Refer to service parts list, page 7 for Do not disassemble detector with fluid
more information. supplied to detector or line pressurized.
Remove pressure and supply before
disassembly.
Failure to comply may result in death or
serious injury.

Notice
! Electronic controller module is non-
repairable. Replace detector if electronic
controller module is found to be damaged
or faulty.

4
Detector disassembly Fig. 1

1 Remove head bolts (2.4) and washers (2.3) Wire pin connections
from cover (2.1) († fig. 3).
2 Remove the detector cover (2.1) and 1 Ground
o-ring (1.4). 2 Output signal 1 3
3 Positive V DC
3 Remove oval gears (1.2, 1.3).
4 Clean and inspect all parts. Replace any
suspect, worn or damaged components.
2

Fig. 2

Digital
Signal (black)
Flow sensor cable V DC (brown) Input
Ground (blue) PLC or
controller

DC power + V DC
+V DC
source Ground blue

Ground

Fig. 3

2.1 2.3
2.4

1.2 1.3
1.1

1.4

5
Detector assembly 4 Place cover (2.1) on detector body (1.1),
taking care not to damage o-ring (1.4).
1 Align rib on top of cover (2.1) with “magnet” 5 Install washers and bolts (2.3, 2.4),
on body (1.1) († fig. 4). tightening bolts in a diagonal pattern to
2 Insert both gears at 90° angles to each 0.73 ft.lbf (1 Nm).
other († fig. 4). 6 Visually check that the cover assembly (2.1)
3 Lightly grease the o-ring (1.4) and place it in has been pulled down evenly († fig. 4).
the detector body (1.1).
Testing procedure
1 Apply 12 to 30 V DC to pin 1 and 3 of con-
nector († fig. 1 page 5).
2 Apply low air pressure or pressurized
Notice
! Check gear rotation by turning
grease ( by grease gun, for example) to any
port of the detector.
either gear.
3 As a result of this action, the gears should
If gears are not in mesh correctly or do
turn, and LED should begin blinking.
not rotate freely, remove one gear and re-
place correctly at 90° to other gear
(† fig. 4). Notice
! If gears do not turn or LED is not
blinking, perform assembly steps again.

Fig. 4

1.1
2.1
1.4

1.3
1.2

90°

6
 Fig. IPB 1

1.2 1.3
1.1
1.4
2.1

2.3, 1.5
2.4, 1.6

2.2
3, 4, 5, 6
2.1

Service parts/kits

Item no. Pat no. Description Qty

1 280135 Body assembly kit 1

1.1 Body assembly 1
1.2 Oval gear
1
1.3 Gear with magnet 1
1.4 Square o-ring 4
1.5 Washer

1.6 8-32 x .75 THD-Lock.SHC screw 4

2 280136 Cover assembly kit
2.1 Cover assembly
1
2.2 Square o-ring 4
2.3 Washer 4
2.4 8-32 x .75 THD-Lock.SHC screw

3 1) 280137-03 Cable assembly 9.8 ft. (3 m) 1

41) 280137-15 Cable assembly 49.2 ft. (15 m) 1
51) 280137-30 Cable assembly 98.4 ft. (30 m) 1

61) 280137-45 Cable assembly 147.6 ft. (45 m) 1

1) Must be ordered separately.

7
 Troubleshooting*

Problem Possible cause Remedy

Detector never registers grease No signal from magnet. Check magnets and gear if required.
output.

Damaged controller/PCB. Replace detector.

No grease passed through detector even The system detected a failure correctly
lubrication cycle occurred without delivering grease and lubrication device like the injector or
to detector’s inlet. grease line needs to be checked.

Media flow is below minimum required flow rate. Increase input.

Dirt particles jamming the rotors. Remove rotors and remove any dirt and
contamination.

Low viscosity of media. Use grease grade 0 to 2.

Air in the system. Purge air from system.

The detector is not registering Bad contact between connector and outlet wire Replace wire connector.
grease output every lubrication cycle. connector.
(Detector miss signal.)

Low input of media. Increase input.

Grease leakage. Screw loose or missing. Tighten screws.

Damaged o-ring. Replace o-ring.

The detector pressurized over maximum Replace the detector and reduce inlet
pressure rating. pressure.
*Indicates change.

8
Declaration of conformity
Declaration of conformity according the EMC
directive 2014/30/EU.

We declare that the model of the Digital grease

flow detector in the version supply by us, com-
plies with the provisions of the above men-
tioned directive.

Applied harmonized standard in particular:

EN61326-1 Electrical equipment for meas-
urement, control and laboratory use. EMC requirements-
Part 1: General requirements (IEC 61326-1)

Declaration of conformity according to direc-

tive 2014/35/EU relating to low voltage.

Safety evaluation.

We declare that the model of the Digital grease

flow detector in the version supplied by us,
complies with the provisions of the above
mentioned directive.
Applied harmonized standards in particular:
EN61010-1 Safety requirements for electri-
cal equipment for measurement, control and
laboratory use -Part 1:
General requirements (IEC 61010-1).

Robert Hoefler
Director Product Development and Product Engineering
St. Louis, MO

Made in USA
5148 N. Hanley Road
St. Louis, MO 63134

9
11
Warranty
The instructions do not contain any information on the
warranty. This can be found in the General Conditions of
Sales, which are available at: www.skf.com/lubrication.

® SKF is a registered trademark of the SKF Group.

® Lincoln is a registered trademark of Lincoln Industrial Corp.
© SKF Group 2016
The contents of this publication are the copyright of the publisher
and may not be reproduced (even extracts) unless prior written
permission is granted. Every care has been taken to ensure the
accuracy of the information contained in this publication but no
liability can be accepted for any loss or damage whether direct,
indirect or consequential arising out of the use of the information
contained herein.
PUB LS/I4 15881/1 EN.R2 · July 2016 Form 400101B